© 2003 IFS AB. All rights reserved. April 17, 2017

Process Automation Integration Utilizing ABB’s 800xA and OPC © 2003 IFS AB. All rights reserved. April 17, 2017

The Integrated Plant System Customer - Supplier B2B / B2E Delivery Confirmation Internet Purchase order ERP / EAM Customer order Rescheduling Analysis and Optimization Inventory Maintenance AIP There are a lot of new possibilities when you connect the ERP/EAM systems with the automation equipment. A customer order can be put via the Internet. The ERP software is aware of the customer orders, the inventory situation and the status of the production line. An intelligent production scheduling can be created based on this and transferred directly to the production equipment. An incident or an alarm during the production can carry out a Work Order to solve the problem. At the same time a re-scheduling can be made taking into account that the production line now is limited. During production the Equipment Monitoring and other systems for analyze and optimization can be fed with data from the automation equipment. You could even define online volumes or weights as order points for your inventory parts and make each part create a purchase order based on a signal indicating that the volume or weight for reordering is reached. The area that is called ”Vertical Integration” or ”Integrated Plant System” is an area where we will see a lot of activity in the years to come. In this borderland between traditional ERP/EAM systems and automation equipment almost nothing has been done so far. Right now we are taking the first steps into a future where these system will be integrated in real time to create better and faster decisions and decision support and to optimize the usage of any asset to its best. Scheduling Plant status Alarm or Incident Material refill Production data Automation equipment / Production © 2003 IFS AB. All rights reserved. April 17, 2017

AIP/800xA as an Integration Platform IFS Maintenance Aspect System Fault Report Active WO Object Info OEE Aspect System Aspect Integrator Platform / 800xA Aspect System Process Portal Asset Optimization © 2003 IFS AB. All rights reserved. April 17, 2017

Equipment cost analysis Asset Cost Reduction Information Availability Seamless navigation between different information systems Work order history Active work orders Business performance By using AIP for integration between systems from different vendors, all data will be available from all participating systems. The ability for seamless navigation between different information systems and with the object as key is based on the Aspect objects integration platform. With a single mouse click the user navigates from the objects graphical representation to the technical description, open up the active work orders, investigates the situation of spare parts for the object in the inventory, creates a fault report, etc. Every information that is of interest is there by a mouse click and presented in the same user interface. A seamless integration of different software. Equipment cost analysis Equipment data sheet OEE P&I Diagram Electrical diagram © 2003 IFS AB. All rights reserved. April 17, 2017

Object Synchronization To achieve Asset Cost Reduction, it is vital that the various systems that contains assets can be synchronized – both in batch and online. AIP/800xA IFS V-101 Object is created and inserted in Equipment functional structure BizAPIs Object with a functional object aspect is created LU LU LU The online synchronization will work in the background and create IFS-objects when an AIP-objects are created and vice versa. For this integration to work as desired, links between object types in AIP and Equipment object types in IFS and object levels have to be set up prior to activating the on-line object synchronization. (Note: There are some restrictions that apply if you want an AIP object to be created when an IFS-object is created since this requires events to be present in IFS Equipment business logic, and these events haven’t been included nor has it been decided if and when to include these events in the standard release.) Database © 2003 IFS AB. All rights reserved. April 17, 2017

Condition-based Maintenance Calendar-based PM could be compared to a man that visits his doctor once a month and asks him to open up his stomach to see if everything looks good. With the risk of forgetting his scalpel or infecting the wound before stitching the stomach together again, the doctor usually says it looks alright. The goal should be to let the factory – as well as men – ask for maintenance when it is needed. The most obvious result of combining ERP/EAM with automation equipment is perhaps the possibility to carry out condition based maintenance. Today most preventive maintenance is carried out based on calendar scheduling. This could be compared to a man that once a month visits a doctor and ask him to open up the stomach to see if everything looks good. With the risk to forget his scissors or infect the wound before stitching the stomach together again, the doctor usually says it look alright. The goal should be to let the factory – as well as men – ask for maintenance when it is needed. By monitoring field equipment we could carry out maintenance based on operational hours, number of starts, calculations of experience data, etc. This could lower the amount of maintenance and at the same time maybe increase the service level of the plant. © 2003 IFS AB. All rights reserved. April 17, 2017

Condition-based Maintenance Seamless access to the maintenance system from the operators environment Automation equipment triggers maintenance actions based on real time information Fault Report Wizard PDA event Operator input Direct input Monitoring PM / WO Event Asset Monitors Collecting data from field devices Detection In the ABB environment Maintenance triggers is developed. More or less advanced calculations can implicate that an action has to be carried out. A work order is creating based on the information calculated in the ABB environment to execute what has to be done. A maintenance trigger could be based on an alarm, an event, a situation with many parameters, etc. IFS could also feed the ABB systems with actual operational hours, etc, as a ground for triggering maintenance. Of cause the operators are able to create fault reports directly from the operators SCADA system and intelligence field devises could create maintenance triggers and report the information using the field bus structure. In the IFS Maintenance system work orders could be handled in many different environments. Traditional Windows or Web clients but also PDA’s or WAP telephones are used to carry the information about work description, material, purchase, crafts, etc. The goal is to deliver a suitable and easy to use interface for every kind of user and to make the maintenance system a true tool for the personnel. PM Event Alarms / Events IFS WO/ PM module Parameters Operational hours, etc. Predictive maintenance © 2003 IFS AB. All rights reserved. April 17, 2017

Overall Equipment Efficiency It’s all about how to increase profit through cost reduction activities as well as real performance enhancements! Time $ Maximum performance Lost profit Real performance (OEE) Maintenance, Engineering and Procurement costs © 2003 IFS AB. All rights reserved. April 17, 2017

How is production capacity used? Total available time Planned stop time Planned stop time Planned production time Unplanned stop time A Available operating time Reduced speed P Net operating time Q Quality losses Value adding operating time 32 19 © 2003 IFS AB. All rights reserved. April 17, 2017

Overall Equipment Efficiency – Without automation integration Manual OEE Data acquisition leads to poor quality of the OEE index! Availability Manual registration - If remembered! Performance OEE Database An event occurs: - Start/Stop - Speed change - Quality loss Yield (Quality rate) OEE is an important key figure in any continues process. It calculates the production as part of the theoretical maximum production limit for the plant. The calculation is based on registering of start, stop, change in speed and quality losses. By registering the stop time, the time where we run at a speed under the max and counting the quality losses we calculate an OEE index. We also have the possibility to drill down to see the reasons from which we have created the existing losses. The problem is that all of the registration is done manually – with a poor quality of data as a result. OEE index = Availability x Performance x Yield © 2003 IFS AB. All rights reserved. April 17, 2017

Overall Equipment Efficiency – With automation integration Real-time data acquisition of OEE events by utilizing OPC Availability Monitoring Performance Operator adds data and submits registration Yield (Quality rate) Collecting OEE data from process equipment By letting the automation equipment feed the ERP system with real time data from the production we would at any time get all OEE data registered. We could present a pre-entered window for the operator to submit – and with the possibility to add data before doing so. This would dramatically increase the quality of the data and for the first time ever we could trust the index that is calculated. Start / Stop - events OEE Web portlet OEE Database Speed change - events Quality losses © 2003 IFS AB. All rights reserved. April 17, 2017

Demo Integrated Plant System Level 1: Connectivity © 2003 IFS AB. All rights reserved. April 17, 2017

Asset Information – Demands, Spare parts, Inventory © 2003 IFS AB. All rights reserved. April 17, 2017

In this slide the operator highlights one of the objects in the process portal – a screw conveyor… © 2003 IFS AB. All rights reserved. April 17, 2017

By right-clicking, he brings up the aspect menu and selects Equipment Data to retrieve detailed information about teh object from the maintenance system. © 2003 IFS AB. All rights reserved. April 17, 2017

The functional object form is displayed The functional object form is displayed. In this form, information about demands, supplier warranties and spare parts is displayed. For each spare part, information about quantity on hand from the inventory also is shown. © 2003 IFS AB. All rights reserved. April 17, 2017

Work Order Planning © 2003 IFS AB. All rights reserved. April 17, 2017

In this slide, the operator have brought up the aspect menu for the screw conveyor. When selecting the “Active Work Orders” aspect, the system will open up the maintenance system, showing active work orders for the selected object. © 2003 IFS AB. All rights reserved. April 17, 2017

This slide shows the active work orders for the object This slide shows the active work orders for the object. In this window, the operator also finds information about status for each work order and planned start date. It is also possible to access more detailed information about a specific work order by using the action-menu in the work order form or by clicking the line number to the left of a work order. © 2003 IFS AB. All rights reserved. April 17, 2017

Document Management © 2003 IFS AB. All rights reserved. April 17, 2017

The ”Connected Documents” aspect, provides access to all documents associated with an object. © 2003 IFS AB. All rights reserved. April 17, 2017

By using the action menu for a document, the operator can easily get a copy of the document, in this case a circuit diagram. © 2003 IFS AB. All rights reserved. April 17, 2017

The view copy of the circuit diagram, in this case a pdf-file, is displayed in Acrobat reader. From this view, the operator can print the document for further actions. © 2003 IFS AB. All rights reserved. April 17, 2017

Fault Reporting © 2003 IFS AB. All rights reserved. April 17, 2017

Filing fault reports in teh maintenance system is only a mouse-click away. The fault report wizard can either be started from an object or from an alarm. In each case, as much information as possible will be inherited from the object/alarm and thus predefined in the wizard to reduce the amount of information that is needed to enter in the wizard and to avoid typing errors. © 2003 IFS AB. All rights reserved. April 17, 2017

When the wizard is completed, the operator receives a receipt that the fault report has been created. In this case Fault Report #200123. © 2003 IFS AB. All rights reserved. April 17, 2017

By bringing up the Active Work Orders aspect... © 2003 IFS AB. All rights reserved. April 17, 2017

...the operator can see that the new fault report (#200123) has been filed in the maintenance system in status Fault Report. In the status field, the operator can follow the status of the fault report from fault report, through observed, planned, etc. up to the point when the work order is completed. The operator also have instant access to information about when the work is planned to be carried out. When the work is completed and possibly costs are authorized, the work order will end up in the history. Historical work orders are also available as an aspect. © 2003 IFS AB. All rights reserved. April 17, 2017

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© 2003 IFS AB. All rights reserved. April 17, 2017